Outdoor unit of air conditioner

ABSTRACT

An outdoor unit for an air conditioner is provided. The outdoor unit has a control box in which a plurality of electronic components are installed. Electronic components from the components inside the control box that radiate the most heat are installed closer to a blower fan that forcibly circulates air.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority under 35 U.S.C. 119 and 35U.S.C. 365 to Korean Patent Application No. 10-2007-0120356 (Nov. 23,2007), which is hereby incorporated by reference in its entirety.

BACKGROUND

The present disclosure relates to an outdoor unit of an air conditionerhaving a control box with an internal configuration divided intomultiple stages to separate the respective electrical components fromone another.

In general, an air conditioner is a cooling/heating system that cools anindoor environment by continually performing a cycle of suctioning warmair from the indoor environment, performing heat exchange between theair and cold refrigerant, and expelling the cooled air back into theindoor environment. For heating, reverse conditions are employed to heatthe indoor environment. The air conditioner performs sequential cyclesusing a compressor, condenser, expansion valve, and evaporator.

Such air conditioners may be divided largely into split system airconditioners with an outdoor unit and an indoor unit installedseparately from each other, and integrated air conditioners with theoutdoor unit integrally installed with the indoor unit.

A relatively recent phenomenon is the widespread use of multi unit airconditioners that are effectively applied in households wanting toinstall two or more air conditioners, and in buildings with multipleoffices that respectively require an air conditioner. A multi unit airconditioner connects one outdoor unit to a plurality of indoor units toachieve the same effect as installing a plurality of split system airconditioners.

In the different types of air conditioners described above, a pluralityof electrical components is housed in a control box within the outdoorunit. Such control boxes may not be able to perform their functionsproperly due to excessive heat they may radiate.

Also, because the electrical components are arranged side by side alonga single surface within the control box, each component is affected byheat generated from other neighboring components. Such an arrangementalso makes product assembly difficult.

SUMMARY

Embodiments provide an outdoor unit of an air conditioner with a controlbox partitioned into a plurality of installation spaces to separate eachelectronic component.

Embodiments also provide an outdoor unit of an air conditioner thatenables a control box to be hooked and fixed onto a frame assemblyprovided within a cabinet.

Embodiments further provide an outdoor unit of an air conditioner with acontrol box provided with a catching rib and a fastening end tofacilitate fastening of the control box.

In one embodiment, an outdoor unit of an air conditioner includes: acontrol box including a plurality of built-in electronic components,wherein those of the electronic components generating more heat areinstalled in proximity to a blower fan that forcibly circulates air.

In another embodiment, an outdoor unit for an air conditioner, includes:a front panel defining a front exterior of the outdoor unit; and acontrol box in which a plurality of electronic components is disposed,wherein the front panel defines a servicing window to allow manipulationof the control box from a front exterior, and the control box isprovided with an inspection window at a front surface thereof to enableinspection of a state of the air conditioner.

In a further embodiment, an outdoor unit for an air conditioner,includes: a cabinet defining an overall exterior of the outdoor unit; ablower fan forcing an upward discharging of air; a frame assemblyprovided within the cabinet to support the blower fan; and a control boxprovided at a side of the frame assembly, and including a plurality ofelectronic components within, wherein the control box is hooked andfixed to the frame assembly.

In an outdoor unit of an air conditioner according to the presentdisclosure, the inside of a control box is partitioned into a pluralityof compartments to install electrical components in positions separatedfrom one another. Accordingly, effects of heat generated by eachelectrical component on other components are reduced. Also, becauseassembly, repair and maintenance can be performed separately for eachcomponent, work efficiency can be improved.

Further, the top end of the control box according to the presentdisclosure is hooked and fixed onto the frame assembly, and a catch riband a fastening end are provided on the top end of the control box.Thus, to fasten the control box, the top end thereof is first hookedonto the frame assembly, after which a screw may be used for fastening,thereby making installation easier.

The details of one or more embodiments are set forth in the accompanyingdrawings and the description below. Other features will be apparent fromthe description and drawings, and from the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an outdoor unit according to a preferredembodiment of the present disclosure.

FIG. 2 is an exploded perspective view of an outdoor unit according to apreferred embodiment of the present disclosure.

FIG. 3 is right-side view of an installed control box according to anembodiment of the present disclosure.

FIG. 4 is a diagram showing a front panel of a control box.

FIG. 5 is a perspective view showing the internal structure of a controlbox according an embodiment of the present disclosure.

FIG. 6 is an exploded perspective view showing the internal structure ofa control box according to an embodiment of the present disclosure.

FIG. 7 is an exploded perspective view showing the internal structure ofa control box according to another embodiment of the present disclosure.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Reference will now be made in detail to the embodiments of the presentdisclosure, examples of which are illustrated in the accompanyingdrawings.

FIG. 1 is a perspective view of an outdoor unit according to a preferredembodiment of the present disclosure. Specifically, FIG. 1 exemplarilyshows a type of outdoor unit for an air conditioner that discharges airupwards.

As shown in FIG. 1, the outdoor unit 10 has a hexahedral exterior shapeand is connected through pipes to a plurality of indoor units (notshown). Refrigerant flows between the outdoor unit and indoor units.

The outdoor unit 10 has its lower exterior defined by a base assembly100, and includes a cabinet 200 provided above the base assembly 100 toform the remaining exterior thereof. Also, outlet grills G have anoctagonal shape (when viewed from above) and protrude upward from thetop of the cabinet 200 to discharge air upward through the outlet grillsG.

FIG. 2 is an exploded perspective view of an outdoor unit 10 accordingto a preferred embodiment of the present disclosure.

As shown in FIG. 2, the cabinet 200 is formed with a plurality ofpanels. In more detail, a pair of front panels 210 and 212 is providedat the front end of the base assembly 100 to define the front exteriorof the outdoor unit. That is, a front left panel 210 and a front rightpanel 212, which have shapes of rectangular flat plates, are provided asa pair installed on the left and right, and a front center frame 220 isvertically elongated between the front left panel 210 and the frontright panel 212.

A pair of front upper panels 230 and 232 is further provided above thepair of front panels 210 and 212. The front upper panels 230 and 232form the front upper exterior of the outdoor unit, and include a frontupper left panel 230 and a front upper right panel 232 at the left andright, respectively. A front upper frame 240 is further provided betweenthe front upper left panel 230 and the front upper right panel 232. Thefront upper frame 240 is shaped correspondingly to the front centerframe 220, and supports the pair of front upper panels 230 and 232.

A left panel 250 and a right panel 260 are provided at the left andright ends, respectively, of the base assembly 100, defining the leftand right external facets of the outdoor unit. Also, a left grill 252 isintegrally formed with the left panel 250, and a right grill 262 isintegrally formed with the left panel 260. Thus, outside air is able toenter the outdoor unit 10 through left grill 252 and the right grill262.

A pair of rear grills 270 is provided at the upper rear end of the baseassembly 100. The rear grills 270 define the rear exterior surface, andair enters the outdoor unit 10 from the rear thereof through the reargrills 270.

A rear center frame (not shown) is further provided at the centralportion of the pair of rear grills 270 opposite the front center frame220 to support the pair of rear grills 270.

A pair of top panels 280 and 282 is provided between the top ends of theleft panel 250 and the right panel 260 to define the top exterior of theoutdoor unit. That is, the external top surface of the outdoor unit 10is defined by the rectangular left top panel 280 and right top panel282. An outlet 284 is defined vertically through each of the pair of toppanels 280 and 282.

Also, the outlet grills (G) are installed on the outlets 284. The outletgrills (G) prevent impurities from the outside from entering through theoutlets 284, and also allow air inside to be discharged upwards.

A pair of rear upper panels 290 and 292 is further provided at the topof the pair of rear grills 270. The rear upper panels 290 and 292 definethe rear upper exterior of the outdoor unit, and are formed tocorrespond in shape to the front upper panels 230 and 232.

Accordingly, the rear upper panels 290 and 292 include a rear upper leftpanel 290 and a rear upper right panel 292 at the left and right sides,and a rear upper frame 294 is further provided between the rear upperleft panel 290 and the rear upper right panel 292. The rear upper frame294 is formed in a shape corresponding to the front upper frame 240, andsupports the pair of rear upper panels 290 and 292.

A frame assembly 300 is provided within the cabinet 200. The frameassembly 300 is for supporting shrouds 420 and 422, a blower fan 400,and other components (to be described below), and is installed on thetop ends of the front panels 210 and 212.

A pair of blower fan 400 and fan motor 410 assemblies is installed atthe top of the frame assembly 300. The pair of blower fans 400 isenclosed by a pair of shrouds 420 and 422. That is, a left shroud 420and a right shroud 422 having the same shape are installed at the top ofthe frame assembly 300, and a blower fan 400 is disposed to the insideof the pair of shrouds 420 and 422.

A heat exchanger 450 is installed within the cavity 200. The heatexchanger 450 functions to exchange heat between refrigerant flowingtherein and air from the outside, and is installed on the upper leftend, rear end, and right end of the base assembly 100. That is, the heatexchanger 450 is formed in a ‘∩’ shape as shown (when viewed fromabove).

A servicing window 514, allowing manipulation of a control box 500(described below) from outside the front, is formed on the front panels210 and 212, or specifically, on the front right panel 212. That is, asshown, a rectangular servicing window 514 is formed through the frontright panel from the front to rear thereof.

Also, the servicing window 514 is selectively sealed by a servicingcover 516. The servicing cover 516 has a shape and size corresponding tothe size and shape of the servicing window 514. That is, it is arectangular plate corresponding in size to the servicing window 514.

FIG. 3 is a right-side sectional view of a control box 500 installed thecabinet 200 according to an embodiment of the present disclosure.

As shown in FIG. 3, the control box 500 is installed rearward of thefront panels 210 and 212. The control box 500 is a portion that controlsthe operation of the air conditioner, and has a plurality of electroniccomponents within. Also, the blower fans 400 are disposed above thecontrol box 500. Therefore, after air outside the outdoor unit 10 entersthe outdoor unit 10, it is discharged upward, as shown in FIG. 3.

FIGS. 4 to 7 show the structure of a control box 500 in detail. That is,in FIGS. 4 and 5, the front surface and right section are shown, FIG. 6is an exploded perspective view showing the front of a control boxdetached, and FIG. 7 is an exploded perspective view showing theinternal structure of the control box 500.

As shown in the diagrams, an inspection window 501 is formed at thefront of the control box 500. The inspection window 501 allows the stateof the air conditioner to be inspected. A plurality of components suchas a display 501a is further installed in the inspection window 501. Thedisplay 501 a is a portion displaying the state of the air conditioner.

The inspection window 501 is formed in a position corresponding to theposition of the servicing cover 516. Thus, when the servicing cover 516is removed, the inspection window 501 is exposed to the outside throughthe servicing window 514.

The inside of the control box 500 is partitioned into a plurality ofcompartments in which electronic components are installed, and form airpassages 502 to dissipate heat generated by the components.

In further detail, partitioning plates 510 and 512 are provided in theinner, central portion of the control box 500 to partition the spacewithin the control box 500 into a plurality of compartments. As shown inthe drawings, the partitioning plates 510 and 512 include an uppersupporting plate 510 and a lower supporting plate 512 that are providedat the upper and lower portions of the control box, respectively.

The upper supporting plate 510 and the lower supporting plate 512 haverectangular flat plate shapes, and partition the inner space of thecontrol box 500 roughly into a frontal (the left side, in FIG. 5)compartment, and a rear (the right side, in FIG. 5) compartment.

In FIG. 5, the upper supporting plate 510 and the lower supporting plate512 are installed to be separated from one another. Alternately,however, the upper supporting plate 510 and the lower supporting plate512 may be connected or integrally formed.

Further, partitioning plate mounting brackets 518 (in FIG. 7) areprovided in the control box 500, for the partitioning plates 510 and 512to be fixed and mounted thereon. The partitioning plate mountingbrackets 518 are installed at the left and right sides of the controlbox, respectively, facing one another, and respectively fix the left andright ends of the partitioning plates 510 and 512.

Between the partitioning plates 510 and 512 (or the upper supportingplate 510 and the lower supporting plate 512) and the rear surface (theright side in FIG. 5), a predetermined space is defined. An air passageis defined vertically by the space. That is, an air passage 502 isformed, through which air from the outside that enters an inlet 520 (tobe described below) ascends.

In more detail, air that enters through one end (the lower end) of thecontrol box 500 passes along the air passage 502 and is dischargedthrough the other end (the upper or rear end).

Accordingly, the inlet 520 and an outlet 522, for air entry anddischarge, are respectively formed in the control box 500. The inlet 520and outlet 522 are defined in different surfaces. That is, the inlet 520is formed vertically through the lower surface of the control box 500,and the outlet 522 is formed from front to rear through the rear surface(the right surface in FIG. 5) at the upper portion of the control box500.

In addition, a rain blocker (not shown) for preventing the entry ofrainwater is further formed on the outlet 522. That is, becauserainwater can enter the control box 500 from the outside through theoutlet 522 formed at the rear surface (or right surface in FIG. 5) ofthe control box 500, the rain blocker, for preventing infiltration ofrainwater, is formed to extend rearward on the outlet 522.

The rain blocker may be sloped so that its position rises graduallytoward the rear (the right in FIG. 5). This is to allow air dischargedrearward (to the right in FIG. 5) through the outlet 522 to be smoothlyexpelled upward from the outdoor unit 10.

A plurality of electronic components is installed within the control box500. Of these, the components that generate comparatively more heat areinstalled proximately to the blower fan 400 that forcibly induces flowof air. That is, the components that generate comparatively more heatare mounted at the upper portion within the control box 500 in proximityto the blower fan 400.

Specifically, a main printed circuit board (PCB) 530, a terminal block532, and a magnet switch (SW) 534 are installed in the front portion(the left side in FIG. 5) of the control box 500. That is, a maincontroller 530 is installed on the upper supporting plate 510 providedat the top, and the terminal block 532 and magnet S/W 534, etc. areinstalled on the lower supporting plate 512 provided at the bottom.

Furthermore, components such as a reactor 540 and inverter controller541, a noise filter 542, and a fan controller 543 are installed in therear portion (the right side in FIG. 5) of the control box 500. That is,the reactor 540 and inverter controller 541 are installed at the rear(the right side in FIG. 5) surface of the control box 500, and the noisefilter 542 and the fan controller 543 are installed at the lower portionthereof.

Moreover, a heat sink 550 for dissipating heat is provided at the rearsurface (the left surface in FIG. 5) of the control box 500. The heatsink 550 includes a plurality of heat dissipating fins, and projectsrearward (to the left in FIG. 5) from the control box 500.

A heat pipe 552 through which refrigerant flows is located within theheat sink 550. The heat pipe 552 consists of a thin pipe that extendsvertically, and refrigerant is filled inside the heat pipe 552.

Accordingly, the refrigerant filled in the heat pipe 552 flowsvertically to uniformly transfer heat to the heat sink 550 in a verticaldirection. Thus, the heat sink 550 may be provided in plurality, so thatheat can be dissipated evenly along the entire surface area of the heatsink 550.

A plurality of heat dissipating ribs 544 is further provided at the rearend (the right end in FIG. 5) of the reactor 540, to support the reactor540 and aid in heat dissipation.

Further, the control box 500 is hooked and fixed onto the frame assembly300. That is, the top end of the control box 500 is hooked and fastenedto the frame assembly 300, and the front surface is fastened to thefront right panel 212.

The top end of the control box 500 includes a catching rib 560 forhooking onto the frame assembly 300, and a fastening end 562 forfastening to the frame assembly 300.

In further detail, the fastening end 562 protrudes upward from theleading upper edge of the control box 500, and the catching rib 560 bentand extending rearward is formed at the central upper end of thefastening end 562.

In addition, either end of the fastening end 562 respective defines afastening hole 564 in which a screw fastens, and a catching slot (notshown) is recessed rearward into the leading end of the frame assembly300 for the catching rib 560 to insert into.

Thus, after the catching rib 560 is inserted in the catching slot (notshown) defined in the leading end of the frame assembly 300, screws maybe used to fix the control box 500 to the frame assembly 300.

A front fastening end 566 is formed at both the left and right sidesurfaces of the control box 500. The front fastening end 566 is tightlyfixed by means of the screw to the front right panel 212.

The flow of air in an outdoor unit of an air conditioner configuredabove according to the present disclosure will be addressed in detailbelow.

First, referring to FIG. 3, the overall flow of air throughout theinside of the outdoor unit 10 is an upward airflow within the outdoorunit 10, induced by the rotation of the blower fan 400.

Accordingly, the outdoor air flows into the outdoor unit 10 through therear grill 270, left grill 252, and right grill 262. The air issuctioned-by the blower fan 400, moves upward to flow into the shrouds420 and 422, and is discharged upward through the outlet grill G.

Here, external air contacts the outer surface of the control box 500 ina primary stage, and during this process, heat exchange occurs by meansof the heat sink 550 formed on the outside of the control box 500. Also,the heat pipe 552 within the heat sink 550 increases the heat exchangingeffectiveness of the heat sink 550 (see FIG. 5).

Next, FIG. 5 will be referred to in describing the flow of air withinthe control box 500. Here, the blower fan 400 forcibly circulatesairflow in an upward direction, and the discharging of air through theoutlet 522.

Accordingly, air is suctioned through the inlet 520, and the airsuctioned through the inlet 520 flows upward through the air passage502, after which it passes through the outlet 522 to be discharged tothe rear (the right side in FIG. 5) of the control box 500. Then, theair enters the shrouds 420 and 422, and is discharged to the upperportion of the outdoor unit 10.

To describe the installation process of the control box 500, first, thecatching rib 560 formed on the control box 500 is inserted into thecatching slot (not shown) defined in the leading end of the frameassembly 300. Thus, the upper end of the control box 500 catches on theframe assembly 300.

Next, a screw is inserted and fastened in the fastening hole 564 of thefastening end 562. Thus, the upper end of the control box 500 is firmlyfixed to the frame assembly 300.

Then, a screw is used to fasten a front fastening end 566 of the controlbox 500 to the front right panel 212. Through this procedure, thecontrol box 500 is firmly fixed to the frame assembly 300 and the frontright panel 212.

Although embodiments have been described with reference to a number ofillustrative embodiments thereof, it should be understood that numerousother modifications and embodiments can be devised by those skilled inthe art that will fall within the spirit and scope of the principles ofthis disclosure. More particularly, various variations and modificationsare possible in the component parts and/or arrangements of the subjectcombination arrangement within the scope of the disclosure, the drawingsand the appended claims. In addition to variations and modifications inthe component parts and/or arrangements, alternative uses will also beapparent to those skilled in the art.

1. An outdoor unit for an air conditioner, comprising a control boxincluding a plurality of built-in electronic components, wherein thoseof the electronic components generating more heat are installed inproximity to a blower fan that forcibly circulates air.
 2. The outdoorunit according to claim 1, wherein the control box further comprises apartitioning plate provided within the control box to partition an innerspace of the control box into a plurality of compartments, thepartitioning plate fixed at both side edges to partitioning platemounts.
 3. The outdoor unit according to claim 2, wherein rear surfacesof the partitioning plate and the control box define an airflow passagetherebetween, through which air flows.
 4. The outdoor unit according toclaim 2, wherein components generating less heat are installed at afront portion within the control box, and components generating moreheat are installed at a rear portion within the control box.
 5. Theoutdoor unit according to claim 4, wherein the control box furthercomprises: a main PCB (printed circuit board), a terminal block, and amagnet switch installed in the front portion; and a reactor, an invertercontroller, a noise filter, and a fan controller installed in the rearportion.
 6. The outdoor unit according to claim 5, wherein the controlbox further comprises a heat sink for dissipating heat provided ona,rear surface of the control box.
 7. The outdoor unit according toclaim 6, wherein the heat sink comprises a built-in heat pipe throughwhich refrigerant flows.
 8. An outdoor unit for an air conditioner,comprising: a front panel defining a front exterior of the outdoor unit;and a control box in which a plurality of electronic components isdisposed, wherein the front panel defines a servicing window to allowmanipulation of the control box from a front exterior, and the controlbox is provided with an inspection window at a front surface thereof toenable inspection of a state of the air conditioner.
 9. The outdoor unitaccording to claim 8, wherein the servicing window is selectivelycovered with a servicing cover.
 10. The outdoor unit according to claim8, wherein the inspection window comprises a display displaying thestate of the air conditioner.
 11. An outdoor unit for an airconditioner, comprising: a cabinet defining an overall exterior of theoutdoor unit; a blower fan forcing an upward discharging of air; a frameassembly provided within the cabinet to support the blower fan; and acontrol box provided at a side of the frame assembly, and including aplurality of electronic components within, wherein the control box ishooked and fixed to the frame assembly.
 12. The outdoor unit accordingto claim 11, wherein the control box further comprises: a catching ribat an upper end of the control box to catch on the frame assembly; and afastening end at the upper end of the control box to fasten to the frameassembly.
 13. The outdoor unit according to claim 12, wherein thefastening end is formed to protrude upward from a leading portion of theupper end of the control box.
 14. The outdoor unit according to claim13, wherein the catching rib is bent downward and extends from a centralupper portion of the fastening end.
 15. The outdoor unit according toclaim 14, wherein the frame assembly defines a catching slot recessedrearward into a leading end of the frame assembly, and the catching ribinserts in the catching slot.